Semi-absorbent, semi-resistant, breathable fabric

ABSTRACT

A semi-absorbent, semi-resistant, breathable fabric includes a single-layer having a first, hydrophilic side that absorbs water, and a second, hydrophobic side; wherein the first, hydrophilic side of the single-layer fabric quickly spreads out a liquid that is absorbed laterally to a wider area such that the absorbed liquid does not seep or pass through to the second, hydrophobic side of the single-layer fabric under gravitational force. A method of making a semi-absorbent, semi-resistant, breathable fabric includes: subjecting a first side of a single-layer fabric to a hydrophilic amino functional polysiloxane softener; treating a second opposite side of the fabric with a fluorocarbon compound under low pressure such that the fluorocarbon compound penetrates no more than half of the fabric thickness; and drying and curing the fabric, preferably at a temperature of about 145° C. to 155° C. for about three minutes to about five minutes.

COPYRIGHT STATEMENT

All of the material in this patent document is subject to copyrightprotection under the copyright laws of the United States and othercountries. The copyright owner has no objection to the facsimilereproduction by anyone of the patent document or the patent disclosure,as it appears in official governmental records but, otherwise, all othercopyright rights whatsoever are reserved.

FIELD OF THE INVENTION

The present invention generally relates to the field of textile materialthat has application in moisture management, breathability, and waterresistance. In particular, the present invention relates tosemi-absorbent, semi-resistant, breathable fabric.

BACKGROUND OF THE INVENTION

In conventional textile fabrics used in a mattress pad, hosiery itemsand other apparels, the top layer comprises a normal fabric and a bottomlayer generally contains waterproof laminated nonwoven fabrics. Polywadding generally is provided in-between these to give a bulky and softfeel imparting comfort properties. During daily use, a liquid substancelike tea, coffee, and soft drinks, or any other liquid, may accidentallybe spilled onto or otherwise come into contact with the bed, whereuponthe fitted sheet absorbs the same and the liquid passes through to thetop layer of the mattress pad and further passes through the waddinglayer, wherein it is entrapped above the bottom layer inside thewadding. This liquid remains inside the wadding layer and may graduallystart giving off a pungent smell. Bacterial and fungus growth also mayresult, and dust mites may thrive, which causes allergens.

U.S. Pat. No. 5,735,145 discloses a multi-layer weft knit fabric forabsorbing moisture and wicking it from a first fabric layer to a secondlayer, as well as a method for making the fabric. The multi-layer fabricincludes a first hydrophobic layer and a second hydrophilic layer, withthe layers being secured together by a series of courses forming spaceryarns, which maintain the fabric layers in a spaced relationshiprelative to each other. The spacer yarns are adapted to wick moisturefrom the hydrophobic layer to the hydrophilic layer. The spacer yarnsare preferably knit-in or laid-in to the respective knit fabric layers,and a plastic water-resistant layer is secured proximate the hydrophilicfabric layer. A method of integrally knitting the multi-layer fabric ona circular knitting machine is also described. The weft knittedmultilayer fabric is selected from polyester, nylon, and polypropylene.

U.S. Pat. No. 6,806,214 discloses a mattress cover including a compositefabric comprising a hydrophobic material and a hydrophilic material onboth sides of a fabric layer, the composite fabric being a single layerincluding an inner exposed surface of the hydrophobic and hydrophilicmaterials that is predominantly the hydrophobic material which ispolypropylene, and an outer surface of the hydrophobic and hydrophilicmaterials that is predominantly the hydrophilic material which is one ofpolyester and cotton, the fabric providing a one-way liquid transportsystem transporting liquid away from the inner surface towards the outersurface.

United States Patent Application Publication No. 2007/0261173 disclosesa spacer fabric in combination with an infant mattress pad. The spacerfabric has three parts or components knitted together to form a fabricwith two breathable outer fabric layers and a breathable cushionedmiddle defined by yarns interconnecting the two layers. The spacerfabric is incorporated into an infant mattress pad in order to create aninfant safety and comfort system designed to help reduce the risk ofsudden infant death syndrome (SIDS) and also to provide infants withenhanced comfort.

U.S. Pat. No. 6,277,770 discloses an allergen-barrier fabric comprising:a fabric substrate, woven from 0 to 45% continuous synthetic filamentyarns and 55 to 100% natural or synthetic spun yarns, wherein the fabricprovides a barrier to mite-induced allergen particles. Theallergen-barrier fabric further comprises a fluoro-chemical finish onthe fabric, wherein the finish provides protection against fluid stains.

U.S. Pat. No. 6,511,927 discloses a breathable and waterproof textilelaminate, said laminate comprising a microporous membrane comprising ahydrophobic film having a plurality of pores of a size large enough toallow water vapor to pass there through but small enough to inhibit thepassage of liquid water; a nonporous layer bonded to said microporousmembrane, which is expanded polytetrafluoroethylene, with a firstadhesive to protect the microporous membrane from contaminants, saidnonporous layer comprising a hydrophilic material capable of allowingthe diffusion of water vapor there through; and a fabric layer adheredto one of the microporous membrane and the nonporous layer with a secondadhesive. One of the first and second adhesives comprises a hydrophilicadhesive and the other comprises a non-breathable discontinuous nonhydrophilic adhesive. The four fabric layers are laminated with an ePTFElayer.

United States Patent Application Publication No. 2012/0276797 disclosesa barrier fabric, which is selected from cotton textile and/or a mixtureof cotton and polyester, with a nanofibrous layer for mechanicalretention of organic substances. The barrier fabric is formed by asandwich structure containing a basic material from unwoven fabric of“spun bond” type, to which at least one nanofibrous layer is arranged,selected from the group comprising a hydrophilic polymer, a hydrophobicpolymer, or in the case of double-layer arrangement, a combination ofthe hydrophilic polymer in one layer and the hydrophobic polymer in theother layer. The nanofibrous layer is equipped with a protectivecovering layer, and the individual layers of the sandwich are connectedto each other. The nanofibrous layer is used as a barrier againstpenetration of allergens produced by the dust mites through theupholstery material of mattresses, pillows, bedclothes or softfurnishings. The hydrophobic polymer material is selected frompolyurethane or from PVDF fluoro-polymer, or from their co-polymersrespectively. The nanofibrous layer is made from the hydrophilic polymerPA6 of the polyamide group.

In view of the foregoing, it is believed that a need exists for a fabrichaving properties of concurrent absorbency, breathability, and waterresistance, thereby providing hygienic properties to the fabric andcomfort to the user. One or more aspects and features of the presentinvention are believed to address such need.

SUMMARY OF THE INVENTION

The present invention includes many aspects and features.

Accordingly, in an aspect of the invention, a fabric comprises a firstsurface on which a liquid is quickly absorbed and spread over a widearea such that the liquid does not percolate or pass through to theopposite side of the fabric under gravitational force. A related aspectrelates to a process for manufacturing such a fabric.

In another aspect of the invention, a single layer fabric is breathableas well as semi-absorbent on one side, but semi-resistant on the otherside, whereby the absorbency and breathability of the fabric ensuresuser comfort properties of the fabric and the property of not allowingthe water to seep through the single-layer fabric imparts hygienicproperties of the fabric.

In another aspect of the invention, a semi-absorbent, semi-resistant,breathable fabric comprises a single-layer having a first, hydrophilicside that absorbs water, and a second, hydrophobic side. The first,hydrophilic side of the single-layer fabric quickly spreads out a liquidthat is absorbed laterally to a wider area such that the absorbed liquiddoes not seep through to the second, hydrophobic side of thesingle-layer fabric under gravitational force.

In a feature of this aspect, the fabric comprises natural fibers.

In a feature of this aspect, the fabric comprises synthetic fibers.

In a feature of this aspect, the fabric comprises regenerated fibers.

In another feature of this aspect, the fabric comprises a combination ofone or more natural fibers, one or more synthetic fibers, and one ormore regenerated fibers.

In a feature of this aspect, the fabric is woven.

In another feature, the fabric consists of a woven single-layer fabric.

In another feature, the fabric comprises a single layer of woven fabriccomprising weft yarns and warp yarns, wherein each of the weft yarns andthe warp yarns extends on both sides of the single layer of fabric andis hydrophilic on the first side and hydrophobic on the second side.

In another feature, the fabric comprises a single layer of woven fabriccomprising weft yarns and warp yarns, wherein each of the weft yarns andthe warp yarns includes at least a first extent that is hydrophilic andat least a second extent that is hydrophobic relative to the firstextent.

In another feature, the fabric comprises a single layer of woven fabriccomprising weft yarns and warp yarns, each of which has a uniformabsorbency along its length, the hydrophilic and hydrophobic propertiesbeing imparted to the single layer of fabric after the fabric has beenwoven.

In another feature of this aspect, the thread count of the fabric is inthe range of 120 TC to 1200 TC.

In a feature of this aspect, the yarn count of the fabric is in therange of 30 s count to 120 s count.

In another aspect, a method of fabricating a semi-absorbent,semi-resistant, breathable fabric comprises the steps of: (a) subjectinga first side of a single-layer fabric to hydrophilic amino functionalpolysiloxane softener; (b) treating a second, opposite side of thefabric with a fluorocarbon compound under low pressure such that thefluorocarbon compound does not penetrate more than 50% of the fabricthickness; and (c) drying and curing the fabric to obtain thesemi-absorbent, semi-resistant, breathable fabric.

In a feature of this aspect, step (c) comprises drying and curing at atemperature range of 145° C. to 155° C. for a time range of betweenthree minutes and five minutes.

In a feature of this aspect, the fluorocarbon compound comprises; (i) afluorocarbon emulsion, and (ii) a paste consisting of an acrylic crosslinking polymer; urea; a handle modifier and softener; a syntheticthickening agent; a fixing agent; an antifoaming agent; a liquorammonia; and water.

In a feature of this aspect, the fluorocarbon compound comprises: (i) afluorocarbon emulsion, and (ii) a paste comprising 10% by weight of anacrylic cross linking polymer; 3% by weight of urea; 2% by weight of ahandle modifier and softener; 1.8% by weight of a synthetic thickeningagent; 0.5% by weight of a fixing agent; 0.5% by fabric of anantifoaming agent; 1% by weight of a liquor ammonia; and 81.2% by weightof water.

In a feature of this aspect, the ratio by weight of fluorocarbonemulsion to the paste is 25:75.

Additional aspects include a mattress pad, pillow, bed sheet, comforter,mattress, apparel, sportswear, industrial fabrics, and geotextiles, eachmade with the semi-absorbent, semi-resistant, breathable fabric inaccordance with one or more of the foregoing aspects and features; andmethods of making such a mattress pad, pillow, bed sheet, comforter,mattress, apparel, sportswear, industrial fabrics, and geotextiles.

In yet another aspect, a textile product, such as a mattress pad,comprises: a single layer of woven fabric; a layer of wadding; and anonwoven fabric defining an enclosure in which the wadding is contained.The single layer of fabric comprises a hydrophilic side and anoppositely facing hydrophobic side, with the single layer of fabricbeing stitched to the enclosure in covering relation to a top side ofthe enclosure, and with the hydrophilic side of the single layer offabric facing away from the enclosure and the hydrophobic side facingthe enclosure. Liquid that may be spilled onto or otherwise come intocontact with the top side of the mattress pad is absorbed by thehydrophilic side of the single layer of fabric on the top side of themattress pad, spreads across the hydrophilic top side of the mattresspad, and does not seep through to the hydrophobic area of the singlelayer of fabric or to the wadding layer.

In a feature, the nonwoven fabric is waterproof or water resistant. Inan alternative feature, the nonwoven fabric is not waterproof or waterresistant.

In another feature, the mattress pad further comprises a skirt fabric oredge fabric stitched to the enclosure.

In another feature, the single layer of fabric comprises a breathable,woven fabric comprising warp and weft yarns, each of the yarns includingat least a first extent that is hydrophilic and at least a second extentthat is hydrophobic relative to the first extent.

In another aspect of the invention, a mattress pad comprises a layer ofwadding located between a single layer of woven fabric on a top side ofthe mattress pad and a nonwoven fabric on a bottom side of the mattresspad. The single layer of fabric comprises a hydrophilic side facing awayfrom the layer of wadding and an oppositely facing hydrophobic sidefacing toward the layer of wadding, the hydrophilic side of the singlelayer of fabric defining a top of the mattress pad.

In addition to the aforementioned aspects and features of the presentinvention, it should be noted that the present invention furtherencompasses the various logical combinations and subcombinations of suchaspects and features. Thus, for example, any aspect may be combined withan aforementioned feature in accordance with the present inventionwithout requiring any other aspect or feature.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more preferred embodiments of the present invention now will bedescribed in detail with reference to the accompanying drawings.

FIG. 1 is a schematic cross-sectional view of single-layer fabric inaccordance with one or more preferred aspects and features of thepresent invention, wherein (a) indicates an upper, semi-absorbent sideand (b) represents a lower, semi-resistant side, “semi-absorbent” and“semi-resistant” referring to the water absorbency of the respectivesides of the fabric.

FIG. 2 is a schematic cross-sectional view of a single-layer fabrichaving a fabric construction showing an interlacement between warp yarn(c) and weft yarn (d), wherein it is demonstrated how the single-layerfabric provides a semi-absorbent area on one side (a) and asemi-resistant area on the other side (b).

FIG. 3 is a schematic cross-sectional view of the single-layer fabric ofFIG. 2, wherein a liquid droplet (e) is shown coming into contact withthe semi-absorbent side (a) on the upper fabric surface.

FIG. 4 is a schematic cross-sectional view of the single-layer fabric ofFIG. 3, wherein the liquid droplet (e) has begun to spread laterallyacross the fabric, remaining only within the upper semi-absorbentportion of the fabric of side (a) without the liquid droplet (e) passingdownward through the fabric seeping into the semi-resistant bottomportion of the fabric of side (b).

FIG. 5 is a schematic cross-sectional view of a mattress pad thatincludes the single-layer fabric of FIG. 1, wherein callout (f) denotesa wadding layer, callout (g) denotes normal nonwoven fabric, and callout(s) denotes a skirt fabric or edge fabric.

FIG. 6 is a schematic cross-sectional view of conventional mattress pad,wherein callout (i) denotes a conventional top layer fabric, callout (f)denotes a wadding layer, callout (e) denotes is a liquid drop passingthrough the top layer fabric into the wadding layer, callout (h) denotesa laminated waterproof fabric, callout (g) denotes a normal nonwovenfabric, and callout (s) denotes a skirt fabric or edge fabric.

DETAILED DESCRIPTION

As a preliminary matter, it will readily be understood by one havingordinary skill in the relevant art (“Ordinary Artisan”) that the presentinvention has broad utility and application. As should be understood,any embodiment may incorporate only one or a plurality of theabove-disclosed aspects of the invention and may further incorporateonly one or a plurality of the above-disclosed features. Furthermore,any embodiment discussed and identified as being “preferred” isconsidered to be part of a best mode contemplated for carrying out thepresent invention. Other embodiments also may be discussed foradditional illustrative purposes in providing a full and enablingdisclosure of the present invention. As should be understood, anyembodiment may incorporate only one or a plurality of theabove-disclosed aspects of the invention and may further incorporateonly one or a plurality of the above-disclosed features. Moreover, manyembodiments, such as adaptations, variations, modifications, andequivalent arrangements, will be implicitly disclosed by the embodimentsdescribed herein and fall within the scope of the present invention.

Accordingly, while the present invention is described herein in detailin relation to one or more embodiments, it is to be understood that thisdisclosure is illustrative and exemplary of the present invention, andis made merely for the purposes of providing a full and enablingdisclosure of the present invention. The detailed disclosure herein ofone or more embodiments is not intended, nor is to be construed, tolimit the scope of patent protection afforded the present invention,which scope is to be defined by the claims and the equivalents thereof.It is not intended that the scope of patent protection afforded thepresent invention be defined by reading into any claim a limitationfound herein that does not explicitly appear in the claim itself.

Thus, for example, any sequence(s) and/or temporal order of steps ofvarious processes or methods that are described herein are illustrativeand not restrictive. Accordingly, it should be understood that, althoughsteps of various processes or methods may be shown and described asbeing in a sequence or temporal order, the steps of any such processesor methods are not limited to being carried out in any particularsequence or order, absent an indication otherwise. Indeed, the steps insuch processes or methods generally may be carried out in variousdifferent sequences and orders while still falling within the scope ofthe present invention. Accordingly, it is intended that the scope ofpatent protection afforded the present invention is to be defined by theappended claims rather than the description set forth herein.

Additionally, it is important to note that each term used herein refersto that which the Ordinary Artisan would understand such term to meanbased on the contextual use of such term herein. To the extent that themeaning of a term used herein—as understood by the Ordinary Artisanbased on the contextual use of such term—differs in any way from anyparticular dictionary definition of such term, it is intended that themeaning of the term as understood by the Ordinary Artisan shouldprevail.

Regarding applicability of 35 U.S.C. §112(f), no claim element isintended to be read in accordance with this statutory provision unlessthe explicit phrase “means for” or “step for” is actually used in suchclaim element, whereupon this statutory provision is intended to applyin the interpretation of such claim element.

Furthermore, it is important to note that, as used herein, “a” and “an”each generally denotes “at least one,” but does not exclude a pluralityunless the contextual use dictates otherwise. Thus, reference to “apicnic basket having an apple” describes “a picnic basket having atleast one apple” as well as “a picnic basket having apples.” Incontrast, reference to “a picnic basket having a single apple” describes“a picnic basket having only one apple.”

When used herein to join a list of items, “or” denotes “at least one ofthe items,” but does not exclude a plurality of items of the list. Thus,reference to “a picnic basket having cheese or crackers” describes “apicnic basket having cheese without crackers”, “a picnic basket havingcrackers without cheese”, and “a picnic basket having both cheese andcrackers.” Finally, when used herein to join a list of items, “and”denotes “all of the items of the list.” Thus, reference to “a picnicbasket having cheese and crackers” describes “a picnic basket havingcheese, wherein the picnic basket further has crackers,” as well asdescribes “a picnic basket having crackers, wherein the picnic basketfurther has cheese.”

Additionally, as used herein to modify “fabric”, the phrases“semi-absorbent” and “semi-resistant” refer to water absorbent and waterresistant fabric properties of opposite sides of a fabric such that oneside has a greater affinity for absorption than the other and a gradientexists with respect to water absorbency properties along the thicknessof the fabric. Preferably the absorbent or water resistant properties ofthe fabric lies approximately in the range of 40% to 60%.

Referring now to the drawings, one or more preferred embodiments of thepresent invention are next described. The following description of oneor more preferred embodiments is merely exemplary in nature and is in noway intended to implicitly limit the invention, its implementations, oruses.

FIG. 1 is a schematic cross-sectional view of a single layer of fabricin accordance with one or more preferred aspects and features of thepresent invention, wherein callout (a) indicates an upper,semi-absorbent side of the fabric and callout (b) represents a lower,semi-resistant side of the single layer of fabric. It will beappreciated from FIG. 1 that the two sides (a),(b) define the singlelayer of fabric, and that each side (a),(b) has a respective depth, withthe combined depths defining the thickness of the single layer offabric.

FIG. 2 is a schematic cross-sectional view of the single-layer fabric ofFIG. 1, in which an exemplary construction of the fabric also isrepresented. The fabric construction shows an interlacement between warpyarns (c) and weft yarns (d) resulting from weaving of the yarns. Anyconventional weaving procedure may be utilized; the fabric weave can beplain, satin, twill, dobby, jacquard, etc.

Preferably the fibers of the warp yarns and weft yarns are selected fromnatural fibers, synthetic fibers, or regenerated fibers, such as forexample, cotton, rayon, polyester, or any other such fiber blends.Furthermore, the fibers preferably do not exhibit hydrophilic andhydrophobic properties; such properties of the fabric preferably areimparted through chemical processing that is performed on the fabricitself, described below, and not with the usage of hydrophilic orhydrophobic yarn.

In some embodiments, a yarn that is used in weaving the fabric prior tochemical processing of the fabric has a homogenous water-absorbency orwater-resistant characteristic; after the chemical processing, thewater-absorbency or water-resistant characteristic varies (alternatesbetween being hydrophilic and hydrophobic, relatively speaking) alongadjacent extents of the yarn.

The fabric further may have different characteristics depending on thematerial used and preferably is woven from between 120 TC to 1200 TC,and the finish can be done on the fabric made from 30 s yarn count to120 s yarn count. In a preferred embodiment, the compact, single layer,woven fabric that is semi-absorbent, semi-resistant, and breathable ismade from 100% cotton.

With reference now to FIGS. 3 and 4, desired absorption characteristicsof the fabric are described. In this respect, FIG. 3 is a schematiccross-sectional view of the single-layer fabric of FIG. 2, wherein aliquid droplet (e) is shown coming into contact with the semi-absorbentside (a) on the upper fabric surface; and FIG. 4 is a schematiccross-sectional view of the single-layer fabric of FIG. 3, wherein theliquid droplet (e) has begun to spread laterally across the fabric,remaining only within the upper semi-absorbent portion of the fabric ofside (a) without the liquid droplet (e) passing downward through thefabric seeping into the semi-resistant bottom portion of the fabric ofside (b).

It thus will be appreciated that absorption of the liquid on the upperside (a) of the fabric results in the absorbed liquid being spread inthe absorbent area of side (a). The hydrophobic area of the fabricconsisting of side (b) that has been treated with fluorocarbon does notgenerally absorb the liquid relative to the hydrophilic side. As aresult of this juxtaposition of side (a) and side (b), the fabricensures that the liquid does not seep through from side (a) to side (b),with the liquid being absorbed and spreading only through thehydrophilic top area of the fabric on side (a). It will further beappreciated that the absorbent side (a) thereby protects the comfortcharacteristics of the fabric on side (b) from being impacted by aliquid seeping through to side (b).

FIG. 4 further illustrates the desired breathability of the fabric viathe dashed arrows.

Preferred Fabrication Methods

Aspects of the present invention also include fabrication methods formaking semi-absorbent, semi-resistant, and breathable fabric. Inpreferred embodiments, a process for making such a fabric comprises:subjecting an upper side of the fabric to a hydrophilic amino functionalsiloxane softener; treating a back side of the fabric with afluorocarbon compound under low pressure, wherein the fluorocarboncompound penetrates up to but not more than approximately 50% of thefabric thickness; and drying and curing of the fabric at a temperaturerange of 145° C. to 155° C. for a duration of time of between threeminutes and five minutes for obtaining the desired product.

The silicone softeners are used in the process to impart hydrophilicityto the upper side of the fabric and are selected from Amino functionalpolysiloxanes.

The fluorocarbon compound is made by mixing two components, namely, (i)a fluorocarbon emulsion; and (ii) a paste consisting of an acrylic crosslinking polymer (about 10% by weight); urea (about 3% by weight); ahandle modifier and softener (about 2% by weight); a syntheticthickening agent (1.8% by weight); a fixing agent (0.5% by weight); anantifoaming agent (0.5% by weight); a liquor ammonia (1% by weight); andwater (81.2% by weight). Depending on the requirement and fabricquality, the ratio for making fluorocarbon paste can vary from 10-40% ofthe fluorocarbon emulsion and 60-90% of the paste. Preferably, the twocomponents are mixed in 25:75 ratio by weight before being applied tothe fabric.

In some preferred embodiment, the fabric that is processed comprises awoven single-layer fabric of cotton yarns. In accordance therewith, thewoven cotton fabric is subjected to singeing de-sizing, washing andprocessing through a conventional bleaching route, and mercerizing. Thisis followed by subjecting the upper side of the cotton fabric tohydrophilic softener treatment. The softener ensures a soft touch to theuser, and the hydrophilic property ensures the absorbency of the upperside of the fabric even after finishing. The fabric is further subjectedto fluorocarbon treatment at the back side of the cotton fabric suchthat the fluorocarbon compound penetrates up to approximately 50% offabric thickness, or which penetration is about 0.1 mm to 0.2 mm. Thefluorocarbons preferably are applied in the paste form through rotaryprinting machine or flat bed printing machine. The fluorocarbon pastecan also be applied through coating or spray applications, etc. Thefabric is dried and cured at a temperature range of 145° C. to 155° C.for a duration of about three to five minutes.

During the curing process the fluorocarbons are fixed on to the fabricwhich ensures the washing durability. The fluorocarbons penetrate up toapproximately 50% of the thickness of the fabric, imparting the waterresistant characteristics to the fabric on side (b). Side (a) is treatedwith hydrophilic softener and remains hydrophilic.

Exemplary Fabrication Process

In a contemplated, exemplary method of manufacturing a preferredembodiment of the present invention, a single-layer woven cotton fabrichaving a thickness of between 0.2 mm to 0.4 mm is constructed with 60 swarp yarn and 80 s count weft yarn and with final thread count 400 TC.The woven cotton fabric is subjected to singeing de-sizing, washing andprocessing through conventional bleaching route, and mercerizing. Thisis followed by subjecting an upper side of the fabric to a hydrophilicamino functional polysiloxane softener treatment. A fluorocarbon isapplied in the paste form through a rotary printing machine or flatbedprinting machine on a back side of the fabric such that the fluorocarboncompound penetrates up to 0.1 mm to 0.2 mm thickness of the fabric. Thefabric is dried and cured at a temperature of about 145° C. to about155° C. for about three-to-five minutes.

Implementations and Uses

FIG. 5 is a schematic cross-sectional view of a textile product, namely,a mattress pad, in which is utilized a single layer of fabric made inaccordance with a preferred method of the invention. In particular,callouts (a) and (b) denote the single layer of fabric of FIG. 1.Additionally, callout (f) in FIG. 5 denotes a wadding layer, callout (g)denotes a conventional, nonwoven fabric, and callout (s) denotes a skirtfabric or edge fabric.

As illustrated, the single layer of fabric is stitched at the top sideof the mattress pad with absorbent side (a) exposed, with the waterresistant side (b) of the single layer of fabric facing the nonwovenfabric (g). If liquid (e) spills over the mattress pad, the liquid isabsorbed and spreads across the absorbent area (a), and the liquid doesnot seep through the hydrophobic area (b) to the nonwoven fabric (g)adjacent area (b). Due to this, the wadding (f) and nonwoven fabric (g)remains dry and hygienic. In making the mattress pad, the wadding (f) isquilted with nonwoven fabric (g) on top and bottom sides. This quiltedwadding then is attached to the single layer of fabric on all four sidesalong with the skirt.

In contrast to the mattress pad as shown in FIG. 5, a conventionalwaterproof mattress pad is constructed with normal fabric on the topside and nonwoven fabric at the back side. In this respect, FIG. 6 is aschematic cross-sectional view of a conventional mattress pad, whereincallout (i) denotes a conventional top layer fabric, callout (f) denotesa wadding layer, callout (e) denotes is a liquid drop passing throughthe top layer fabric into the wadding layer, callout (h) denotes alaminated waterproof fabric, callout (g) denotes a normal nonwovenfabric, and callout (s) denotes a skirt fabric or edge fabric. Theliquid drop may be a liquid spilled, or may be perspiration of sweatfrom a person lying on the mattress pad, such as when sleeping. Thenormal fabric (i), wadding (f) and normal nonwoven fabric (g) is quiltedtogether and attached to the laminated water resistant nonwoven fabric(h) from all four sides along with skirt. If any liquid (e) spills overthe mattress pad, it gradually penetrates inside the mattress pad andgets entrapped inside the wadding layer (f) by the laminated waterprooffabric (h). After a certain period of time the entrapped liquid may giveoff a pungent smell and bacteria may grow inside the pad due to wet anddamp conditions.

The advantages of the use of preferred embodiments of the invention intextile products will thus be apparent. The finished fabric of theinstant invention is water absorbent at the upper side which allows thewater to absorb and spread whereas the same will not pass through theother side. The said fabric is breathable also. The fabric of thepresent invention stops moisture before reaching fill and allows airflow for temperature comfort. It is anti-allergen and, when used in amattress pad, provides superior mattress protection.

Moreover, preferred embodiments of the invention can be used not only inmattress pads, but also in pillows, sheets, comforters, mattresses,apparel, sportswear, industrial fabrics, and geotextiles, providingcomfort to the user and imparting hygienic properties.

From the foregoing detailed description, it will be appreciated that asingle layer of woven fabric in accordance with one or more preferredembodiment comprises weft yarns and warp yarns, wherein each of the weftyarns and the warp yarns extends on both sides of the single layer offabric and is hydrophilic on the first side and hydrophobic on thesecond side.

Furthermore, it will be appreciated that a single layer of woven fabricin accordance with one or more preferred embodiment comprises weft yarnsand warp yarns, wherein each of the weft yarns and the warp yarnsincludes at least a first extent that is hydrophilic and at least asecond extent that is hydrophilic relative to the first extent.

It also will be appreciated that a single layer of woven fabric inaccordance with one or more preferred embodiment comprises weft yarnsand warp yarns, wherein the single layer of fabric is woven from weftyarns and warp yarns, each of which has a uniform absorbency along itslength, the hydrophilic and hydrophobic properties being imparted to thesingle layer of fabric after the fabric has been woven.

Based on the foregoing description, it will be readily understood bythose persons skilled in the art that the present invention issusceptible of broad utility and application. Many embodiments andadaptations of the present invention other than those specificallydescribed herein, as well as many variations, modifications, andequivalent arrangements, will be apparent from or reasonably suggestedby the present invention and the foregoing descriptions thereof, withoutdeparting from the substance or scope of the present invention.

Accordingly, while the present invention has been described herein indetail in relation to one or more preferred embodiments, it is to beunderstood that this disclosure is only illustrative and exemplary ofthe present invention and is made merely for the purpose of providing afull and enabling disclosure of the invention. The foregoing disclosureis not intended to be construed to limit the present invention orotherwise exclude any such other embodiments, adaptations, variations,modifications or equivalent arrangements, the present invention beinglimited only by the claims appended hereto and the equivalents thereof.

1-8. (canceled)
 9. A method of fabricating a semi-absorbent,semi-resistant, breathable single layer of fabric, comprising the stepsof: (a) subjecting a first side of a single layer of fabric tohydrophilic amino functional polysiloxane softener to imparthydrophilicity to the first side; (b) treating a second, opposite sideof the fabric with a fluorocarbon compound to impart hydrophobicity tothe second side, the treatment being performed under low pressure suchthat the fluorocarbon compound does not penetrate more than 50% of thethickness of the single layer of fabric; and (c) drying and curing thefabric to obtain the semi-absorbent, semi-resistant, breathable fabric.10. The method of claim 9, wherein the method further includes thepreliminary steps for preparation of the single layer of fabric,comprising the steps of singeing, de-sizing, washing and processingthrough a conventional bleaching route, and mercerizing.
 11. The methodof claim 9, wherein the single layer of fabric is woven from weft yarnsand warp yarns, each of which has a uniform absorbency along its length,the hydrophilic and hydrophobic properties being imparted to the singlelayer of fabric after the fabric has been woven.
 12. The method of claim9, wherein said step (c) comprises drying and curing the fabric at atemperature of between 145° C. and 155° C. for a duration of about threeminutes to five minutes.
 13. The method of claim 9, wherein thefluorocarbon compound comprises: (i) a fluorocarbon emulsion, and (ii) apaste consisting of an acrylic cross linking polymer; urea; a handlemodifier and softener; a synthetic thickening agent; a fixing agent; anantifoaming agent; a liquor ammonia; and water.
 14. The method of claim9, wherein the fluorocarbon compound comprises: (i) a fluorocarbonemulsion, and (ii) a paste comprising 10% by weight of an acrylic crosslinking polymer; 3% by weight of urea; 2% by weight of a handle modifierand softener; 1.8% by weight of a synthetic thickening agent; 0.5% byweight of a fixing agent; 0.5% by weight of an antifoaming agent; 1% byweight of a liquor ammonia; and 81.2% by weight of water.
 15. The methodof claim 14, wherein the ratio of fluorocarbon emulsion to the paste is25:75 by weight. 16-28. (canceled)
 29. The method of claim 9, furthercomprising knitting the single layer of fabric as a preliminary step.30. A method of fabricating a semi-absorbent, semi-resistant fabric,comprising the steps of: (a) weaving from weft yarns and warp yarns asingle-layer fabric, each of which yarns has a uniform absorbency alongits length; and (b) imparting hydrophilic and hydrophobic properties tofirst and second opposite sides of the single-layer fabric after thefabric has been woven by, (i) subjecting the first side to hydrophilicamino functional polysiloxane softener to impart hydrophilicity to thefirst side, (ii) treating the second side with a fluorocarbon compoundto impart hydrophobicity to the second side, and (iii) drying and curingthe single-layer fabric to obtain the semi-absorbent, semi-resistantfabric.
 31. The method of claim 30, wherein said step (b)(ii) isperformed under low pressure such that the fluorocarbon compound doesnot penetrate more than 50% of the thickness of the single-layer fabric.32. The method of claim 30, wherein said step (c) comprises drying andcuring the fabric at a temperature of between 145° C. and 155° C. for aduration of about three minutes to five minutes.
 33. The method of claim30, wherein the fluorocarbon compound comprises: (i) a fluorocarbonemulsion, and (ii) a paste consisting of an acrylic cross linkingpolymer; urea; a handle modifier and softener; a synthetic thickeningagent; a fixing agent; an antifoaming agent; a liquor ammonia; andwater.
 34. The method of claim 30, wherein the fluorocarbon compoundcomprises: (i) a fluorocarbon emulsion, and (ii) a paste comprising 10%by weight of an acrylic cross linking polymer; 3% by weight of urea; 2%by weight of a handle modifier and softener; 1.8% by weight of asynthetic thickening agent; 0.5% by weight of a fixing agent; 0.5% byweight of an antifoaming agent; 1% by weight of a liquor ammonia; and81.2% by weight of water.
 35. The method of claim 34, wherein the ratioof fluorocarbon emulsion to the paste is 25:75 by weight.
 36. A methodof fabricating a semi-absorbent, semi-resistant fabric, comprising thesteps of: (a) weaving from weft yarns and warp yarns a single-layerfabric, (i) such that the single-layer fabric has first and secondopposite sides, wherein each side has a respective depth, with thecombined depths defining the thickness of the single-layer fabric, and(ii) such that each yarn extends on and defines part of the first sideand extends on and defines part of the second side of the single-layerfabric; and (b) imparting hydrophilic and hydrophobic properties to thefirst and second opposite sides of the single-layer fabric after thefabric has been woven such that a gradient exists with respect to waterabsorbency properties in a direction along the thickness of thesingle-layer fabric by, (i) subjecting the first side to hydrophilicamino functional polysiloxane softener to impart hydrophilicity to thefirst side, (ii) treating the second side with a fluorocarbon compoundto impart hydrophobicity to the second side, and (iii) drying and curingthe single-layer fabric to obtain the semi-absorbent, semi-resistantfabric.
 37. The method of claim 36, wherein said step (b)(ii) isperformed under low pressure such that the fluorocarbon compound doesnot penetrate more than 50% of the thickness of the single-layer fabric.38. The method of claim 36, wherein said step (c) comprises drying andcuring the fabric at a temperature of between 145° C. and 155° C. for aduration of about three minutes to five minutes.
 39. The method of claim36, wherein the fluorocarbon compound comprises: (i) a fluorocarbonemulsion, and (ii) a paste consisting of an acrylic cross linkingpolymer; urea; a handle modifier and softener; a synthetic thickeningagent; a fixing agent; an antifoaming agent; a liquor ammonia; andwater.
 40. The method of claim 36, wherein the fluorocarbon compoundcomprises: (i) a fluorocarbon emulsion, and (ii) a paste comprising 10%by weight of an acrylic cross linking polymer; 3% by weight of urea; 2%by weight of a handle modifier and softener; 1.8% by weight of asynthetic thickening agent; 0.5% by weight of a fixing agent; 0.5% byweight of an antifoaming agent; 1% by weight of a liquor ammonia; and81.2% by weight of water.
 41. The method of claim 40, wherein the ratioof fluorocarbon emulsion to the paste is 25:75 by weight.